JP5730199B2 - Method and tool for forming a surface having a predetermined roughness - Google Patents

Description

  The present invention provides a surface structure of a predetermined geometry in the form of the superordinate concept of claim 1, in particular a surface structure of a predetermined geometry suitable for applying material by, for example, thermal spraying. The present invention relates to a method for forming a cylindrical surface.

  Furthermore, the present invention relates to a tool for executing such a method and an apparatus for executing the manufacturing method. The components of the present invention further include a suitable combination tool including a honing tool, a handling device formed to handle the tool, and a machine for reproducibly producing a predetermined surface quality and geometry as desired. This is a typical processing method.

  In order to solve certain technical problems, in particular tribological problems, it is often desirable to coat the surface of a support material with a material having highly defined properties that are optimal for the respective use conditions. Such a coating has the advantage that it is a very compact construction type and means that the contact surface of the adjacent material is relatively large with respect to the means for joining a plurality of components mechanically or by bonding or brazing. Thus, this type of coupling technique is provided for components that are particularly thermally loaded. This coating results in a very good material connection and allows the heat energy to be derived particularly well.

  In the field of metal materials, such coatings are often applied by so-called “thermal spraying”, in which case so-called plasma spraying or arc spraying is often carried out in addition to so-called flame spraying. In this case, the powder particles and / or the wire particles are thrown or sprayed with high thermal energy and kinetic energy onto the surface of the substrate to be coated, where a desired coating layer is formed after the temperature has dropped.

  In order to obtain a sufficiently high level of layer deposition, the porosity in the so-called structure, i.e. the encapsulation of hollow chambers that cannot be filled any more, or some of the unmelted particles remain without adhering to the substrate. In addition to strictly adhering to process parameters in order to avoid rebounding so-called "overspray", it is important to ensure that such a manufacturing method is used in order to ensure the mechanical properties between the coating layer and the substrate. It is a perfect joint. In such a case, it is necessary to form a surface structure with a predetermined geometry on the substrate surface. This ensures that the layer is mechanically and uniformly laid over the entire surface to be coated. In this case, it has often been shown that it is often insufficient to roughen and / or activate the substrate surface, for example by sandblasting or water jets.

  For example, when an appropriate coating layer applied by thermal spraying is provided on a cylinder crankcase, a sliding surface with wear resistance and less friction is generated.

  Such a base material to be deposited, for example a steel base material, is exposed to a considerable mechanical load during use, so that in order to obtain a sufficient service life, the covering layer is made of a substrate, for example an aluminum casting. It will be firmly bonded to the substrate in the form of the product. In particular, the surface of the material to be coated will be processed so as to obtain a surface that is particularly well suited for thermal spraying, having precisely defined geometric parameters, In order to ensure sufficient bonding, consideration must be given to defining the manufacturing process so that the desired surface structure can be reproducibly produced with slight variations.

  In this relation, for example, the surface of a base material of an aluminum cast product is processed by cutting with a progressive tool, and the cross section of the groove is processed to a final dimension by cutting teeth that are successively engaged. Is considered. Efforts have been made to provide a predetermined structure on a pre-machined cylindrical surface of, for example, an aluminum casting by means of such a conventional tool of this type. In practice, however, it has been shown that such a structure cannot be formed on a substrate with the same quality and shape accuracy. The adhesion of the coating layer deposited by thermal spraying was then varied over a wide range. That is, it has never been possible to use such a method for mass production.

  Accordingly, an object of the present invention is to provide a predetermined surface structure according to the superordinate concept of claim 1 so that it can be used for mass production of a substrate surface best prepared for thermal spraying. For example, to provide a method for forming a cylindrical surface. Another object of the present invention is to provide such a method that makes it possible to produce a substrate surface optimally prepared for application of material by thermal spraying, particularly economically, with high accuracy and with little shape variation. It is to provide a tool to perform.

  It is a further object of the present invention to provide an apparatus for performing the method using the tool according to the invention.

  This problem is solved by the method steps of claim 1 for the method, by the tool having the features of claim 12 for the tool, and by the device having the features of claim 25 for the device.

  According to the present invention, the groove structure on the substrate surface is formed as follows. That is, first, a base groove having a groove base width smaller than the groove base width of the completed groove is formed, cut, or deformed on the surface of a cylindrical substrate, for example. This base groove is then further optimized for subsequent spraying, which is a subsequent method step, on at least one side or one side of the groove machined into the substrate, with or without cutting. In order to produce a contour prepared in Preferably, at least one side surface of the groove is processed so that an undercut portion or an undercut narrow portion of the groove formed on the surface is formed. Such a narrow portion of the groove provides a very strong bond between the substrate and the coating layer. After the groove structure is processed and formed in such steps, a uniform force is subsequently generated in the engaging tooth row or blade.

  According to an advantageous configuration, the tool can be formed as a progressive tool. Further advantageous configurations are described in the dependent claims.

  It is particularly advantageous if the groove formed by machining with or without cutting is deformed by narrowing the machined groove opening by material compression. Such material compression is preferably performed simultaneously with the production of the groove structure, preferably with the same tool. In this way, a particularly effective undercut portion is formed for firm joining between the spray layer to be applied and the cylindrical surface.

  Experiments have shown that this type of groove side machining does not require the need for so-called “additional cutting fluids” on the tool side. The “additional cutting fluid” is important for the shape accuracy of the groove structure to be formed when processing a relatively soft material such as aluminum. Thus, for example, a cylindrical inner surface has a groove base width of up to 0.18 mm, a depth of about 0.14 mm, a groove pitch of 0.7 mm (groove spiral pitch), and a similar groove shape. An undercut groove can be formed. In this case, the opening of the groove facing the material to be applied can also be limited to a width of 0.12 mm. This provides a particularly good premise for material application by thermal spraying, for example plasma spraying or arc spraying.

  A particularly advantageous method arrangement is described in claim 7. In this case, the desired surface structure is formed, for example with a progressive tool, with the simplest kinematics and thus quickly and economically.

  In order to optimize the meshing between the substrate and the material to be applied, the stepwise processing according to the invention for the formation of the final groove profile allows the surface of the groove structure, i.e. the groove side edges and / or the grooves. The base can be optimized over a wide range. This is done, for example, by providing a microstructure on the machined surface as described in claim 8.

  A tool according to the invention for carrying out the method is provided with pre-processed teeth and safety teeth in front of the dentitions for machining and forming the groove structure, for example of cuboid shaped chips and cutting chips, which teeth It has a slightly projecting dimension that is smaller than that of the groove forming tooth or the molded tooth. Pre-processed teeth and safety teeth can thus be utilized to guide and stabilize the forming and cutting tips as they enter the cylindrical substrate surface. In this way, the teeth of the progressive tool engage the substrate to be machined with great precision. By forming the groove structure in a stepped manner in this way, the force applied to the teeth or blades to be engaged thereafter is kept uniform. This not only improves the accuracy of the groove structure to be produced, but also allows good control of the very small tooth load of the tool. Thus, a tool constructed in this way is no longer prone to “additional cutting fluid supply” as described above in the area of fine teeth, especially with a minimum amount of cutting fluid supply (MMS). Therefore, mass production of a desired microgroove structure having a geometry with little manufacturing error becomes possible for the first time.

  Advantageous further configurations of the method and tool are described in the dependent claims.

  In principle, the method according to the invention can be used for any surface composition of the substrate to be coated. However, if the surface to be coated is formed by the surface of a cylindrical substrate, a particularly successful configuration of this method is obtained. In this case, the groove structure is positioned in a comb-like and redundant manner, like a threading tool in which at least one spiral groove continuously processes one and the same groove on the cylindrical substrate surface. It is formed by machining using a tool supporting a plurality of teeth of different cross sections. In this case, as described in claim 4, it is advantageous if the base groove is deformed and compressed on the surface of the cylindrical substrate. However, it is also possible to form the base groove by cutting.

  The groove structure is formed such that the groove has a very small depth and width in preparation for thermal spraying. Correspondingly, the tool for producing the groove structure is also finely formed. Therefore, if it is further formed by the method of claim 5, it is sufficient to provide a single molded part or cutting part with teeth arranged in comb form for the production of the groove structure. Similarly, however, a plurality of base grooves and a plurality of grooves having an undercut groove cross section can be formed on the surface. Since the working process of cutting or cutting is performed redundantly, a special advantage is obtained that the same groove shape can be produced even when the tool is worn.

  If the method steps (cutting and deformation operations) of the base groove and / or the finished groove structure are divided into partial steps, the force applied to the tool dentition can be better controlled. . Therefore, since the machining or cutting operation process is performed redundantly, a special advantage that the same groove shape can be manufactured even when the tool is worn is obtained.

  A particularly advantageous substrate surface with the best structure for the application of the material by subsequent thermal spraying is obtained by the method of claim 9. By displacing the substrate on the substrate surface with a profile, i.e. a groove structure, only an intermediate groove is obtained which enlarges the contact surface between the substrate and the material applied by thermal spraying. is not. Furthermore, the groove opening can be sufficiently narrowed by the displacement of the substrate material between the recesses of the groove, whereby the spray layer can be particularly effectively and strongly bonded to the substrate material.

  The tool may be formed as a pure forming tool, cutting tool, honing tool, but various processing forms are possible, for example, cutting and forming, or honing and forming, or a combination of cutting and honing. . For example, it is also advantageous to use a honing tool tool structure, such as a grindstone, with a tool insert that can be adjusted radially using an expanding cone for blade positioning. In the configuration as a honing tool, it is advantageous to use a plurality of blade parts evenly distributed over the circumferential surface, for example a plurality of honing strips, which are preferably diamond (PKD) or boron nitride or similar. It serves as a support for the polishing means, i.e., the polishing cone, formed from other shape-stable materials. In this case, the above-mentioned abrasive cone consisting of a bond (ceramic, metal or resin) additionally has advantageously a predetermined geometry which varies over the axial length of the honing strip, so that The predetermined groove shape can be processed and formed stepwise as described above while adjusting the sliding motion in the direction to the relative rotational motion between the honing strip and the substrate.

  According to another configuration, the groove provided by the preceding section of the honing strip is provided because the honing strip performs a radial adjustment movement while performing a relative axial movement with respect to the substrate surface. Gradually cut to full depth.

  That is, with the tool structure modeled on the honing tool, the grooves are more inclined and can intersect based on the reciprocating motion normally performed by the honing tool. Basically, the honing strip can be configured so that the polishing cone is positioned behind the displacement ridge in a predetermined positional relationship with the kinematics during the honing process. The groove narrow portion similar to the undercut described in the relationship of claim 3 is also formed by pressing the material.

  Experiments have shown that an important parameter for good and sustained adhesion of the layer applied by thermal spraying is the mechanical bond between the layer and the substrate. According to the configuration of the method of claim 9 and the configuration of the tool of claim 16, such a machine is provided even if at least one side of the groove machined in the substrate surface is slightly or not undercut. Joint is guaranteed.

  According to another configuration of the tool for carrying out the method, the tool, in particular the cuboid shaped and cutting tips used, can have a particularly long service life. For example, according to claim 15, there are advantageously provided a plurality of contiguous cutting or compression teeth that give shape, thereby machining different successive sides of the groove to be formed, for example undercut And a small cutting force in the individual dentition and thus a relatively long service life of the tool.

  According to another configuration of claim 16, the tools are a cutting tool and a forming tool. Due to the appropriate formation of the pusher, i.e. the pusher has the same protruding dimension as the safety tooth over a given length, the material displaced by the rounded chamfered protrusion is necessarily cut. Is pushed away into the groove, which additionally narrows the groove opening facing the material to be applied. The projecting dimension of the push-down tooth and thus the projecting dimension of the safety tooth is advantageously provided in the pre-prepared hole, i.e. in the pre-prepared substrate hole, with a narrow play fit or a weak press fit of the formed and cutting tips. Dimensioned to be introduced. The safety tooth preferably has a width corresponding to several times the width of at least one groove pre-processed tooth or at least one shaped tooth (for example a dovetail tooth). In this way, the working accuracy of the forming and cutting tip guides and of the tool is further improved.

  As mentioned above, in the production of groove structures with precisely predefined geometries, the grooves are highly accurate and uncontrolled substrate deposition between the teeth even after long-term use of the formed and cutting tips. It is configured so that no object is generated, that is, so-called “additional cutting fluid supply” does not occur. This leads to a large variation in the shape of the groove to be formed and a deviation of the shape when a relatively soft material such as aluminum is processed. In particular, according to the tool configuration of claims 21 and 22, the groove structure can be manufactured while maintaining the same quality in mass production and guaranteeing a long use period of the tool.

  23. If the blade insert part of claim 22 consists of a composite part, the composite part, for example a hard material chip made of polycrystalline diamond (PKD) is mounted on a support part, preferably a hard metal support. The teeth are formed very finely and with the highest possible accuracy, so that the best cutting properties are obtained, in particular where the smallest cutting volume or cutting cross section occurs. Furthermore, the tool can be heavily loaded. This is because the support or the hard metal support that supports the hard material chip or PKD chip gives the tool the necessary stability, strength, and elasticity. Advantageously, the dentition is eroded into the composite tip. In this way, the molded teeth can be formed without any step over the separation joint between the hard metal support and the PKD chip without any problem.

  The further arrangement of claims 23 and / or 24 gives rise to the possibility of an advantageous fine adjustment of the shaped teeth. Thereby, the load of the tooth manufactured with high accuracy can be maintained as uniformly as possible.

  Hereinafter, a plurality of embodiments of the present invention will be described in detail with reference to the drawings.

FIG. 4 is a side view showing a first configuration of a tool for forming a cylindrical inner surface having a surface structure of a predetermined geometry, which has been pre-processed to apply a material by thermal spraying. . It is the figure which showed the end surface of the tool of FIG. 1 seen from the direction of II of FIG. FIG. 3 is an enlarged view of a throwaway tip having a blade insert portion for forming a surface structure, taken along a line III-III in FIG. 1. FIG. 4 is a plan view of the throw-away tip viewed in the direction of IV in FIG. 3. It is the top view which expanded and showed the blade insert part of the structure of FIG. 4 remarkably. FIG. 6 is a cross-sectional view taken along line VI-VI in FIG. 5. It is sectional drawing along the VII-VII line of FIG. It is sectional drawing along the VIII-VIII line of FIG. It is the same figure as FIG. 3 which showed another Example of the throw away tip which has the blade insert part of a different structure. It is the fragmentary sectional view which expanded remarkably and showed the substrate surface structure which can be manufactured with the said tool.

  Below, the cylindrical inner surface of the base material, in particular, the holes prepared or processed to a predetermined size in the cylinder crankcase, so that the layer can be deposited in mass production by a thermal spraying method. The tool that can be processed is explained. By applying such a material by so-called thermal spraying, for example, it is possible to form a bush made of steel with a small amount of other elements, ie an inserted oxide nest and very fine It is formed in the form of a base material having pores. The final dimension of such a layer is about 0.1-0.2 mm, in which case a very smooth surface with very fine pores results after the honing finish of such a layer.

  In order for the material to be deposited by thermal spraying to adhere well to the substrate, ie the aluminum casting material, it is necessary to provide a special surface on the substrate. For this reason, a tooth row is formed between the material layer deposited by thermal spraying and the aluminum casting so as to be reproducible over the entire surface of the substrate with uniform and good quality. The cylindrical inner surface of the cast aluminum base material has an axial length of about 130 mm, for example, when producing a cylinder bush for an internal combustion engine. In this case, a very slight cylinder shape tolerance and surface roughness are obtained. Must be maintained. In this case, the tool according to the invention is configured to machine and form at least one helical groove having a predetermined geometry on the surface of a cylindrical substrate which has already been pre-machined very precisely. This will be described in detail later.

  The entire tool is indicated at 12 in FIG. This tool has a tightening shaft 14 with a hollow shaft cone (HSK), and a base body 16 is connected to the tightening shaft 14. The axis of the tool 12 is indicated by reference numeral 18, and the drawing shows that the tool 12 is a very rigid and shape-stable tool. This is a prerequisite for processing the cylindrical inner surface of an aluminum casting having a predetermined cylindrical shape accuracy.

  A tool cassette 22 having a substantially rectangular parallelepiped shape is mounted in the pocket indicated by reference numeral 20, and this tool cassette 22 is positioned at an angle between the pockets 20 by tightening screws 24. Tightened to one inner surface. Reference numeral 26 designates an eccentric pin. The eccentric pin 26 can be rotated by a suitable tool, such as a hexagon socket wrench, to align the cassette 22 with respect to the axis 18. Therefore, in order to allow such a fine adjustment of the tool cassette 22, the clamping screws 24 enter the corresponding holes in the cassette 22 with play and at an angle with respect to both support surfaces of the pocket 20. It is obvious to do.

  Reference numeral 28 designates a threaded pin. Although not shown in detail, the threaded pin 28 is supported on the mounting surface 30 of the pocket 20, so that the cassette 22 is in contact with the supporting surface located on the radially inner side of the pocket 20 while being in contact with the axis 18. Can be swiveled in a plane parallel to.

  The cassette 22 may be held axially adjustable, preferably finely adjustable, by means of an adjustment pin not shown in detail. This adjustment pin abuts against the end face 32 of the cassette 22 and can be pushed or screwed into the base 16 in a substantially radial direction.

  The tool cassette 22 has a throw-away tip 34, and this throw-away tip 34 is detachably attached to the tool cassette 22 by a central fixing screw 36 that cooperates with a through hole 35 of the throw-away tip 34. .

  The throw-away tip 34 is made of a suitable support material such as steel, in particular tool steel. However, the throw-away tip 34 is substantially the entire length of the throw-away tip 34 at a side edge 38 that can be oriented parallel to the tool axis 18 and thus parallel to the cylindrical substrate surface to be machined. A blade insert portion 40 extending therethrough is supported. In order to explain the details, FIG. 3 and FIG.

  It can be seen that the throw-away tip 34 has a cutout in the region of the side edge 38 that consists of two faces 42 and 44 that are perpendicular to each other. In this notch, a blade insert part 40 in the form of a rectangular parallelepiped having a substantially square cross section is advantageously firmly mounted by brazing. 3 and 4, the throwaway tip 34 with the blade insert portion 40 is shown in a significantly enlarged dimension, but according to the drawing, the throwaway tip 34 is simply about 4 mm thick D34, It can be seen that it has an edge length of about 9.5 mm. The cross section of the blade insert portion 40 having an edge length of about 1.1 mm is correspondingly small.

  The blade insert portion 40 is formed as a composite portion, and a tip 48 made of polycrystalline diamond (PKD) is firmly mounted on a hard metal support 46. The connection between the portions 46 and 48 is made by hard brazing. The flat joint between the hard metal support 46 and the chip 48 or PKD chip 48 is indicated by the reference numeral 50.

  In particular, as shown in FIG. 4, the PKD tip 48 is shorter by a dimension K than the edge length of the hard metal support 46, thereby preventing the risk of damage to the relatively fragile PKD tip 48. In FIG. 4, the PKD chip 48 is schematically shown by hatching.

  Furthermore, it can be seen that the blade insert portion 40 is provided with extremely fine teeth. With this dentition, for example, a groove structure having a predetermined geometry can be precisely formed on the cylindrical surface of an aluminum casting part having an arbitrary diameter, for example, the diameter of a hole in an internal combustion engine cylinder. In this case, at least 1 having a depth T (see FIG. 10) of 0.15 mm and a width B of a maximum size of 0.2 mm, for example, extending spirally over the entire axial length of the cylindrical substrate surface. Two grooves are formed. The pitch S (see FIG. 10) of the grooves 52 is 0.5 to 0.8 mm.

  In order to produce such a groove 52 having the geometry shown in FIG. 10, the blade insert portion 40 is provided with a special tooth row. This will be described in detail below with reference to FIGS.

  5-8 show a plan view and a cross-sectional view of the blade insert portion 40 in a highly enlarged view. The total length L of the blade insert portion 40 is about 9 to 10 mm. The width B40 of the blade insert portion 40 is about 1 mm, similar to the height H40. As shown in FIGS. 6 to 8, the PKD chip 48 has a thickness H48 of about 0.3 to 0.4 mm, and the hard metal support 46 has a thickness H46 of 0.6 to 0.7 mm. Have. The teeth indicated by reference numerals 54-1 to 54-10 are advantageously eroded over their entire height on the lateral surface of the blade insert portion 40, i.e. have the following geometry.

  First, one safety tooth 54-1 is provided in the axial end region. This safety tooth protrudes from the tooth base by its dimension V54-1. The dimension V54-1 is such that the tooth head of the safety tooth 54-1 is located in the final adjusted tool cassette 22 approximately along the cylinder inner wall diameter, ie the pre-machined inner diameter of the substrate to be coated. Is selected. The width of the safety tooth with dimension B54-1 is about 0.3 mm.

  Adjacent to the safety teeth 54-1, two pre-processed teeth 54-2 and 54-3 follow, each spaced by a pitch S. The pre-processed tooth 54-2 has a very thin tooth cross section, but protrudes from the edge of the blade insert portion 40 by a relatively large protrusion dimension V54-2. In other words, the first pre-processed tooth row 54-2 has entered the pre-processed base material surface by a predetermined dimension, and forms a base groove indicated by a one-dot chain line 52B in FIG.

  However, the shape of the first preliminary processing tooth 54-2 is formed such that the width B54-2 of the tooth head is smaller than the width B of the completed groove 52 (see FIG. 10). The protruding dimension V54-2 is selected so as not to reach the diameter DF of the completed contour of the groove 52. For the first time, the base groove is cut to a full depth T (see FIG. 10) by the second preliminary machining teeth 54-3. However, in this case, the width of the groove is maintained to be approximately the dimension B54-2 of the first preliminary machining tooth row 54-2.

  A so-called formed tooth row is followed by being shifted by the pitch S of the groove 52 to be manufactured. These molded teeth are hereinafter referred to as “Pigeon-shaped teeth” 54-4 to 54-7. However, this molded tooth row does not necessarily have to have a side edge that forms an undercut groove when entering the substrate. The shaped dentition can further work with or without cutting.

  In the illustrated embodiment, the dovetail tooth rows 54-4 to 54-7 sequentially process the previously formed base grooves in the groove base region so as to have the final dimension B (see FIG. 10). In this case, the pigeon tail teeth 54-4 and 54-5 are formed by cutting, that is, cutting the groove on one side surface into an undercut groove shape, and then the dove tail teeth 54-6 and 54-. 7 forms the other side surface of the groove by cutting. The engagement of the last dovetail tooth 54-7 results in an undercut groove having the profile shown in FIG. 10, ie, having a depth T and a groove base width B. Instead of cutting, it is also possible to perform deformation without cutting by a formed tooth row.

  Shifted again by the groove pitch S, the last molded tooth or dovetail tooth 54-7 is followed by a so-called roughened surface tooth 54-8, which is a corrugated surface at its tooth head. That is, the rough surface processed portion 56 having a predetermined groove depth in the range of 0.01 mm is formed.

  A so-called cleaning tooth follows the roughened surface tooth 54-8 or a push-off tooth 54-10, which will be further described later. The cleaning teeth can remove cutting residues in the cutting grooves that may occur in some cases. Since the cleaning tooth is indicated by reference numeral 54-9 and is smaller than the tooth height of the molded tooth rows 54-4 to 54-6, the roughened portion 56 is no longer in contact.

  The arranged row of teeth 54-1 to 54-9 ends with a so-called push tooth 54-10. The pusher tooth 54-10 has a tooth head width B54-10, which corresponds to several times the width of the pre-processed tooth or molded tooth. Advantageously, a round chamfered protrusion 58 is formed at the center of the pusher tooth 54-10 having a protrusion dimension V54-10 substantially corresponding to the protrusion dimension V54-1 of the safety tooth 54-1. The protrusion 58 has, for example, a width B58 of about 0.15 mm and a height H58 of about 0.05 mm. The tooth height V54-10 of the pusher tooth 54-10 is selected so as to more or less contact the inner surface of the base material that has been pre-processed to have a predetermined dimension, so that the protrusion of the pusher tooth 54-10. Portion 58 pushes away a relatively soft material of the substrate, for example, a material such as an aluminum cast, laterally and undercut groove 52 laterally, in the region of transition to inner surface 60, the material It is further narrowed by the compression unit 62. Further, the push teeth have a rough surface finish that is reproducible and compensates for wear.

  As can be seen from the above description, the protrusions 58 are positioned at an axial interval A different from the groove pitch S with respect to the cleaning teeth 54-9. This is, for example, 1.5 times the groove pitch S.

  The cross-sectional views of FIGS. 6-8 show how the teeth 54-1 to 54-10 engage the substrate. For example, FIG. 6 shows that the relief angle F54-1 of the safety tooth 54-1 is a value that barely exceeds 0 °. This angle may be negative. When the molding dentition is to process the inner surface of the base material by cutting, the clearance angle F54-1 is positive. Correspondingly, the rake angles of the pre-processed tooth row, the roughened surface teeth 54-8 and the cleaning teeth 54-9 are also positive. On the other hand, the clearance angle F54-10 of the pusher tooth 54-10 is extremely small, particularly in the region of the protrusion 58. Since this angle may even be negative, the pusher teeth 54-10 with protrusions 58 do not cut and the material is pushed away or deformed from the substrate.

  6-8, the wedge angle of the blade insert portion 40 is approximately 90 °, which results in a slightly negative rake angle in the illustrated embodiment.

  As further shown in FIGS. 6-8, the dentitions 54-2 to 54-9 have their height H40 on the blade insert portion 40, i.e., on a hard metal support with a brazed PKD tip. It is processed, preferably eroded so that a uniform tooth height is produced throughout. However, this does not apply to the tooth shape in the region of the safety teeth 54-1 and the pusher teeth 54-10 where the height of the teeth slightly increases with increasing spacing from the blade corner.

  With the above configuration of the tool, the following mode of action occurs when forming a cylindrical inner surface having a predetermined surface structure.

The axis 18 of the tool 12 is oriented concentrically with respect to the axis of the pre-machined cylinder inner wall, so that the radial spacing of the tooth heads of the safety teeth 54-1 is the cylinder inner wall diameter on the substrate surface. To be almost half of The cassette 22 is previously adjusted by means of adjusting means (eccentric pin 26, threaded pin 28) so that the tooth heads of the formed tooth rows 54-4 to 54-7 are oriented substantially parallel to the tool axis 18, so that the tooth If the line is perpendicular to the spiral groove to be formed, the tool can enter the bore. Then, a relative rotational movement between the tool 12 and the substrate cylinder surface is performed, and at the same time, an axial relative sliding movement between the tool 12 and the substrate is performed as follows. That is,
V _R = n _R × S
In this case, V _R is an axial relative speed between the tool 12 and the substrate, n _R is the relative rotational speed between the tool and the substrate.

  As described above, the tool or the dentition of the tool is formed in the region of the blade insert portion 40 such that the dentition has the same cross section throughout the height H40 of the blade insert portion 40. However, I would like to emphasize here that this is not necessarily the case. Rather, the dentitions, in particular the pre-processed dentitions 54-2 and 54-3 and the shaped dentitions 54-5 to 54-8, have a positive lateral cutting angle when machining the groove profile, It may be undercut at least in the region of the side edge.

  As soon as the pre-processed tooth 54-2 cuts or molds the base groove with the groove base width having the dimension B54-2, the next pre-processed tooth 54-3 becomes functional and the base groove is completely Process or cut to a depth T. The pre-processed tooth 54-3 can be omitted, and the first molded tooth 54-4 functions after this. The first shaping tooth 54-4 cuts the first undercut side surface 52-1 so that a groove base portion that is somewhat wider is formed. The groove base is post-processed by the second shaping tooth 54-5, and subsequently the groove base is cut to a full width B / 2 on one side. In the next stage, the molding teeth 54-6 to 54-7 finally cut the other undercut side surface 52-2. Following this, the rough surface finish teeth 54-8 form the rough surface processed portion 56.

  In the above embodiment, the pre-processed tooth 54-2 is formed as a combination tooth similarly to the pre-processed tooth 54-3, and performs both cutting and roughening. However, the pre-processed teeth 54-2 and 54-3 can also be formed as molded teeth or deformed teeth, i.e. teeth that only push away the soft material of the substrate.

  1 to 8 show the insertion of the blade insert portion 40 in a rectangular notch (FIG. 3). The cut-out surfaces 42 and 44 are oriented so that a negative rake angle is produced when the blade insert portion 40 has a rectangular parallelepiped shape. Accordingly, in FIG. 6 to FIG. 8, a surface generated when the surface of the blade insert portion 40 is inclined and worn with respect to the hard metal support 46 by the alternate long and short dash line 64, thereby forming a positive rake angle. Is shown.

  FIG. 9 shows a modified embodiment of the tool, in particular a throw-away tip with a brazed blade insert part. In this throw-away tip, when the hard metal support has an edge surface parallel to the plane like the PKD tip, a wedge angle smaller than 90 ° having a positive rake angle and a positive wedge angle are obtained. Is obtained and this guarantees simple manufacture. For simplicity of explanation, the same reference numerals are given to the components corresponding to the elements of the above embodiment, but the reference numeral “1” is added before.

  It can be seen that the throw-away tip 134 has a notch with a different orientation for the blade insert portion 140. The surfaces 142 and 144 are certainly perpendicular to each other again, but the bottom surface 144 is tilted with respect to the bottom surface 44 of the configuration of FIG. Accordingly, the dentition having the geometry of FIG. 5 is eroded from a rectangular parallelepiped blade insert portion 140 having a hard metal support 146, a PKD tip secured by a hard groove thereon, and an edge length H140. By means of simple manufacturing techniques, positive clearance angles are produced in the pre-formed and molded tooth areas and are reduced by correspondingly controlling the erosion tool in the safety and push-tooth areas. A clearance angle or a negative clearance angle can be formed.

  Extensive experiments have shown that a tool constructed according to the above criteria can be reproducibly machined into a pre-machined cylindrical inner surface of an aluminum casting with the geometry shown in FIG. It was. In this case, supply of additional cutting fluid for aluminum did not occur even after long-term use of the tool. Thus, the surface very suitable for application | coating of a spraying layer was able to be formed in the inner surface of the aluminum casting base material.

  In this case, the important thing is that the blade insert part formed as a progressive tool can be machined very precisely, and the combined construction provides improved stability at critical points, so the blade It can work accurately and reliably over the long term. The combination of cutting teeth and push-in teeth can further emphasize the undercut of the groove 52, which greatly improves the mechanical dentition or engagement between the applied material and the aluminum substrate. .

  Of course, other than the above examples are possible without departing from the basic idea of the present invention. Thus, for example, another hard material such as cubic boron nitride (CBN) or CVD diamond can be used instead of the hard material PKD. It is also possible to work in the area of the blade with another hard material, for example a cermet material.

  The present invention is not limited to providing a groove structure having a predetermined geometry on a cylindrical inner surface. Similarly, a corresponding groove structure can be provided on the outer surface or flat surface, in which case the above method is carried out. In this case, the tool is formed as a planing tool or broach, and the tooth row forms a groove on the entire cross section for each row in the form of a progressive tool.

  The tool has a tooth row extending mainly in the circumferential direction. That is, the blade insert portion 40 is provided with straight teeth. Similarly, the dentition can be tilted somewhat.

  Unlike the above embodiment, the tool 12 may be provided with a plurality of blade insert portions. These blade insert parts are distributed over the circumference, in which case the grooves can be machined, i.e. molded or cut, into the substrate in the form of multi-threads. Such a configuration of the tool results in the form of a honing tool. In this case, the honing strip, which can extend over most of the surface to be machined or over its entire length, has a shape suitable for forming a groove structure.

  The tool can be simply formed as a forming tool, a cutting tool, or a honing tool, but a variety of processing, for example, cutting and forming, and / or honing and forming, and / or a tool that combines cutting and honing Can also be formed. For example, it is also advantageous to use a honing tool, such as a honing broach, with a radially adjustable tool insert, using an expanding cone for blade positioning.

  In the configuration as a honing tool, it is advantageous to use a plurality of blade parts evenly distributed over the circumferential surface, for example honing strips, which are preferably diamond (PKD) or boron nitride or another comparable It serves as a support for the polishing means, i.e. the polishing cone, made of a stable, shape-stable material. The above-mentioned abrasive cone made of a combination (ceramic, metal or synthetic resin) is in this case additionally provided with a predetermined geometry or spatial shape, this shape being in a predetermined form, honing Over the length of the strip in the axial direction, the axial feed movement is adjusted in accordance with the relative rotational movement between the honing strip and the substrate, while the above stepwise or gradual of a given groove structure. It changes so that the processing performed is possible. In this case, the enveloping surface of the polishing means is, for example, a conical circumferential surface, so that the preceding polishing cone in the feed direction projects less from the combination than the subsequent polishing cone. When the honing strip reciprocates in the axial direction, the envelope surface is formed by a bicone that decreases in both axial directions from the axial center.

  According to a variant embodiment, the honing strip performs a radial movement during the axial relative movement with respect to the substrate surface, so that the groove formed by the preceding section of the honing strip is gradually It is cut to become. In this case, the envelope surface of the polishing means can be formed by a cylindrical peripheral surface.

  That is, with the tool configuration modeled on the honing tool, the grooves may be inclined and cross each other by the reciprocating motion of the honing tool that is normally performed. Basically, the honing strip can also be displaced behind the polishing cone in a predetermined positional relationship adjusted to the kinematics of the honing process, so that claim 3 The groove width can be reduced by pushing the material, such as the undercut described above.

  If the tool of FIG. 1 is provided with only one throwaway tip, it is advantageous if the base body 16 is provided with a guide strip distributed over the circumference, which guide strip is connected to the safety tooth. It cooperates to ensure that it is guided in the substrate hole.

  In order not to impair the required shape accuracy of the cylinder, FIG. 1 shows two balance screws denoted by reference numeral 68, and these screws allow fine balance adjustment of the tool.

  In another configuration of the tool, the groove can be formed entirely, i.e. also in the undercut side area.

  The present invention thus provides a method for forming an advantageously cylindrical surface having a surface structure of a predetermined geometry, suitable for applying a material by thermal spraying. In this case, by gradually reducing the groove cross-section to the final dimensions, a slight depth and width is imparted to the substrate to be deposited, preferably pre-processed to a predetermined dimension, preferably a cylindrical surface. A geometrically defined groove structure is formed. Such processing is performed by, for example, a progressive feed tool. In order to mass produce the same quality surface, in the method of the present invention, the groove structure is first formed by machining a base groove having a groove base width smaller than the groove base width of the finished product groove. . The side surfaces of the grooves, for example at least one base groove, are then machined without cutting or by cutting to form an undercut groove profile, in this case advantageously formed by machining The groove structure is deformed by reducing the groove opening by pushing the material.

Claims (19)

A substrate surface (60) pre-machined to a predetermined dimension for forming a cylindrical surface having a predetermined surface structure suitable for coating a material by thermal spraying In addition, a micro- groove structure (52) that is defined in a shape having a slight depth (T) and a width (B) and extends spirally at a predetermined groove pitch (S) is used as a progressive tool. in the formed tool of the type you working adult form,
The groove structure is processed and formed into a cylindrical substrate surface (60), and at the time of this processing and forming, the groove cross section is processed so as to gradually become the final dimension,
First, using the tool teeth (54-1, 54-2, 54-3) , a groove base having a groove base width (B54-2) smaller than the groove base width (B) of the finished groove; A base groove (52B) having two groove side surfaces is processed and formed on the substrate surface (60),
Next, in order to form the groove so as to have a groove cross section of the final dimension undercut , a plurality of molding teeth (54-2 to 54-arranged by being shifted from each other by the groove pitch (S). is 8), closed with a single working process with different cutting or another tooth of the same tool for performing deformation processing, characterized that you processed by or by cutting deformation, the surface structure of a predetermined shape Method for forming a polished surface. Wherein said groove structure formed by machining shaped to deform by narrowing of a material compressing groove opening, The method of claim 1, wherein. The relative rotational movement between the tool and the substrate surface (60) and the axial relative sliding movement between the tool and the substrate are performed simultaneously to form at least one helical groove (52). by processing forming a cylindrical surface to form the trench structure, according to claim 1 or 2 wherein. Wherein when the processing mold the groove cross section, to roughen the surface by material removal, any one process of claim 1 to 3. A cylindrical surface (60), between at least two grooves are preformed (52), an intermediate groove (66) on the same tool is molded by deformation, by which, the groove cross-section of the dovetail, formed in preformed groove structure, any one process of claim 1 to 4. Wherein after forming the groove cross-section of the dovetail, with the same tool, by removing the cutting residue cutting groove, clean the groove cross section, the method according to claim 5, wherein. Processed using the cutting fluid minimal amount (MMS, MQL) performed, any one method according to claims 1 to 6. Tool for carrying out the method according to any one of claims 1 to 7 , comprising a support part (12), on which at least one deformation and cutting is carried out. A tip or cutting tip (34) is attached and the tip is interdigitated in a comb-like manner on a side edge (38) that can be oriented parallel to the cylindrical substrate surface to be processed. At least three teeth (54-1, 54-2, 54-4), of which the first tooth has a first tooth cross section and a first protruding dimension ( V54-1), forming safety teeth (54-1) for guiding the tip (34) when entering the surface of the cylindrical substrate, and at least one adjacent second The second tooth is larger than the second tooth cross section and the first protruding dimension (V54-1). Projection dimension (V54-2) grooves prefabricated teeth and a to form the said base grooves (52B) used to form the cutting, adjacent the second tooth (54-2) At least one third tooth (54-4) is used to transform the base groove (52B) into a groove cross section of the final dimension by deformation or cutting , with at least one lateral side (55). The dovetail shaped formed tooth (54-4) is formed, and the side face (55) allows the tooth head to engage the front of the tooth (54-2) (B54-). 2, a tool for performing a method of forming a surface having a surface structure of a predetermined shape, which is enlarged to a width (B) larger than B54-3). Another groove pre-processed tooth (54-3) is formed between the groove pre-processed tooth (54-2) and the molded tooth (54-4) formed as at least one pigeon-shaped tooth. , Another groove pre-processed tooth (54-3) has a protrusion dimension (V54-3) substantially the same as the protrusion dimension (V54-4) of the molded tooth (54-4). The tool according to claim 8 , wherein the lateral spacing (S) of 54-2, 54-3) and the lateral spacing (S) of at least one shaped tooth (54-4) are the same size. A plurality of adjacent formed teeth (54-4 to 54-7) are provided, and the side surfaces (52-1, 52-2) of the dovetail groove (52) to be formed by these formed teeth. The tool according to claim 8 or 9 , which can be machined. Adjacent to the at least one shaped tooth (54-4 to 54-7) formed as a dovetail-shaped tooth on the side opposite to the safety tooth (54-1), the push away material from the substrate. Teeth (54-10) are formed and the push teeth have the same protruding dimension (V54-10) as the safety teeth (54-1) over a predetermined length (B54-10) 11. A tool according to any one of claims 8 to 10 , wherein the central section has a rounded chamfered protrusion (58). The lateral spacing (A) of the protrusion (58) and the teeth (54-9) adjacent to the protrusion (58) are different from the lateral spacing (S) of the other teeth. The tool according to claim 11 . The safety tooth (54-1) is a number of at least one groove pre-processed tooth (54-2, 54-3) or at least one shaped tooth (54-4) width (B54-2, B54-3). The tool according to any one of claims 8 to 12 , having a width corresponding to double. The groove prefabricated teeth and splines (54-2～54-7) are configured redundantly, thereby, even if the tool is worn, the same groove shape is guaranteed, claims 8 The tool according to any one of up to 13 . The tool according to any one of claims 8 to 14 , wherein the formed teeth (54-1 to 54-10) are made of steel or a hard material which is a wear-resistant material. Molded teeth are formed in the blade insert portion (40) that is firmly mounted in a notch provided in the region of the side edge (38) of the cutting tip (34), the blade insert portion being It has the shape of a prism or rectangular parallelepiped block, and is formed from a composite material. In this composite material, a hard material chip (48) is mounted on a support (46) and molded. 16. Tool according to claim 15 , wherein the teeth (54-1 to 54-10) extend beyond the separation joint (50) of both materials. 17. Tool according to claim 16 , wherein the blade insert part (40) is fixed in shape connection to a cutting tip (34) formed as a throw-away tip. A cutting tip (34) is supported by a tool cassette (22), said tool cassette being on the tool (12), said blade insert portion (40) being approximately relative to the axis of the cylindrical surface (60) to be machined. The tool of claim 17 , wherein the tool is adjustably mounted to be orientable in parallel. Use of a rotary driveable tool and / or a rotary driveable workpiece according to any one of claims 8 to 18 for performing the method according to any one of claims 1 to 6 . In the apparatus, a tool support is provided, the tool support having at least two degrees of freedom of movement, one of the degrees of freedom of movement being relative to the axis of rotation of the tool (12) and / or the workpiece. Parallel tool (12) and / or workpiece feed direction, the other degree of freedom of movement being an adjustment direction extending at an angle relative thereto, the feed being the tool (12) and workpiece An apparatus for carrying out a method for forming a surface having a surface structure of a predetermined shape, characterized in that it can be adjusted according to the relative rotational speed between

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